3D Laser Scanning for Mining Haul Trucks

Engineering-Grade Existing-Condition Data for Repairs, Upgrades and Asset-Life Extension

Mining haul trucks operate under some of the most severe loading and environmental conditions found in industry.

Repeated payload cycles, impact loading, abrasion, corrosion, structural fatigue and previous repairs can gradually change the condition and geometry of a truck body, chassis and associated components. However, engineering teams are often required to plan repairs or modifications without complete, current or reliable dimensional information.

Hamilton By Design provides engineering-grade 3D laser scanning for mining haul trucks, supporting mine operators, maintenance teams, repair contractors, fabricators and equipment suppliers with accurate existing-condition data.

Our scanning services can assist with:

Haul-truck body and tray inspections
Existing-condition documentation
Dimensional verification
Wear and deformation assessment
Reverse engineering
Repair and refurbishment planning
Upgrade and modification design
Replacement component development
OEM and aftermarket component integration
Baseline scans for future condition comparisons
Engineering investigations and failure analysis

The objective is not simply to create a point cloud. It is to provide reliable spatial information that can support better engineering, maintenance and asset-management decisions.

Supporting Mine Operators and OEM Supply Chains

Mining fleets can include equipment supplied by manufacturers such as Caterpillar, Komatsu, Liebherr and Hitachi Construction Machinery.

Depending on the manufacturer and regional terminology, the equipment may be described as:

Mining haul trucks
Mining trucks
Off-highway trucks
Rigid dump trucks
Electric-drive mining trucks
Mechanical-drive mining trucks
Mine-site dump trucks

Caterpillar uses terms including “mining trucks” and “off-highway trucks”, while Komatsu offers construction and mining trucks across a broad payload range. Hitachi commonly uses the term “rigid dump trucks”, and Liebherr refers to its large surface-mining vehicles as mining trucks or haul trucks.

Hamilton By Design provides independent dimensional-capture and engineering-support services. We are not limited to one truck manufacturer, body supplier or repair system.

Our services can support:

Mine owners and operators
Mobile maintenance departments
Asset-management teams
Reliability engineers
Mechanical and structural engineers
Original equipment manufacturers
OEM dealers and service providers
Truck-body manufacturers
Wear-liner suppliers
Refurbishment contractors
Welding and fabrication companies
Mining-equipment modification specialists

Where original drawings and OEM information are available, the captured scan data can be compared with those records. Where drawings are missing, incomplete or no longer representative of the actual truck, the scan can establish a reliable existing-condition reference.

What Parts of a Mining Haul Truck Can Be Scanned?

The scanning scope can be tailored to the maintenance, repair or engineering problem being investigated.

Haul-Truck Bodies, Trays and Tubs

The load-carrying structure of a mining truck may be described as a body, dump body, tray or tub.

These structures are exposed to severe impact and abrasion from loading, haulage and dumping operations. Over time, the body may experience:

Plate wear
Local thinning
Floor deformation
Sidewall distortion
Cracking around welded connections
Misalignment
Impact damage
Fatigue damage
Previous repair build-up
Changes to the original body geometry

A complete 3D scan can capture the accessible internal and external geometry of the body, providing a measurable record for engineering review.

The point cloud may then be used to develop sections, surface comparisons, deformation maps, replacement plate geometry or a simplified solid model.

Chassis and Main Frame

A haul-truck chassis or frame can be scanned to document its existing geometry and the relationship between major structural features.

Scanning may assist with:

Checking general alignment
Locating mounts and interfaces
Documenting previous repairs
Measuring fabricated structures
Establishing component clearances
Planning structural modifications
Developing replacement brackets or supports
Confirming the position of cracks or damaged areas
Recording the frame before and after refurbishment

Laser scanning does not replace non-destructive testing, metallurgical assessment or structural engineering analysis. It can, however, provide the geometric information needed to support those activities.

Wear Components and Liners

Truck bodies may incorporate replaceable wear plates, liners, impact zones and sacrificial components.

Scanning can help document:

Existing liner arrangements
Worn liner geometry
Missing or damaged sections
Mounting-hole locations
Plate boundaries
Floor and sidewall profiles
Interfaces between original and replacement components

The captured data can support the development of replacement liners, wear packages or refurbishment scopes.

Canopies, Handrails, Platforms and Access Systems

Mining trucks may include access platforms, stairs, ladders, handrails, canopies and maintenance structures that have been altered during their operating life.

Scanning can assist with:

Access-system modifications
Replacement platforms
Handrail upgrades
Maintenance-access improvements
Clearance verification
Collision and interference checks
Compliance-review geometry
Fabrication planning

Equipment Mounts and Service Installations

Additional equipment is frequently installed throughout the life of a mining truck.

This may include:

Communication equipment
Cameras and monitoring systems
Fire-suppression equipment
Lighting systems
Electrical cabinets
Hydraulic components
Condition-monitoring sensors
Operator-assistance technology
Autonomous or remote-operation equipment

Scanning provides a spatial record of the available mounting envelope and nearby obstructions before new equipment is designed or installed.

Extending the Useful Life of Mining Assets

A haul truck does not necessarily reach the end of its useful life simply because individual structures or components have become worn.

In many cases, the commercial decision is whether the truck can be economically:

Repaired
Rebuilt
Refurbished
Reconfigured
Upgraded
Repowered
Returned to service
Used for a different operating duty

Reliable existing-condition information helps engineering and maintenance teams make that decision with greater confidence.

Establishing the Actual Condition

Older equipment may differ substantially from the original design information.

The truck may have undergone:

Multiple repairs
Body replacements
Structural modifications
Local strengthening
Wear-plate replacement
Bracket changes
Field alterations
Component substitutions
Damage repairs completed during shutdowns

A 3D scan captures the truck as it exists at the time of inspection.

This allows the project team to design around the actual asset rather than relying solely on drawings that may no longer match the machine.

Reducing Uncertainty Before Refurbishment

Without accurate dimensional data, repair contractors may not identify fit-up issues until worn material has been removed or replacement components are delivered to site.

Scanning can reduce this uncertainty by allowing the team to:

Confirm dimensions before fabrication
Identify deformation before repair work begins
Develop replacement components from the actual geometry
Compare left-hand and right-hand structures
Check whether nominally identical trucks are genuinely interchangeable
Plan repair sequences
Identify areas requiring further inspection
Improve shutdown preparation

This can help reduce rework, site measurement delays and unexpected fabrication changes.

Building a Digital Baseline

A baseline scan creates a dated, measurable record of the asset.

Future scans can then be registered against the baseline to help identify:

Changes in body geometry
Progressive deformation
Areas of material loss
Movement around structural interfaces
Changes following major repairs
Differences between planned and completed work
Recurring damage patterns

The most effective comparison program requires repeatable scan positions, clearly defined reference areas and a consistent data-processing method.

Where surface thickness is important, laser scanning should be combined with appropriate thickness-measurement methods such as ultrasonic testing. Laser scanning measures visible surface geometry; it does not directly measure the remaining thickness of a plate where only one surface is accessible.

3D Scanning for Haul-Truck Body Wear Assessment

A point cloud can provide a highly detailed record of a truck-body surface, but useful wear assessment requires more than collecting data.

A typical workflow may include:

Establishing the inspection objective
Reviewing available OEM or fabrication drawings
Identifying accessible reference surfaces
Cleaning the truck where practicable
Capturing the internal and external body geometry
Registering the scan positions
Removing irrelevant surrounding data
Comparing the scan with a baseline, nominal model or previous scan
Extracting sections through areas of interest
Reporting measurable changes and limitations

Depending on the available reference data, the assessment may compare:

Current scan against an OEM model
Current scan against an original fabrication model
Current scan against a previous baseline
Left side against right side
One fleet truck against another truck
Repaired geometry against pre-repair geometry
Installed components against proposed replacement components

Care must be taken when interpreting differences. A deviation may result from wear, permanent deformation, manufacturing tolerance, previous repair work or the alignment method used during analysis.

For this reason, Hamilton By Design approaches scanning as an engineering measurement activity rather than solely as a visualisation service.

Reverse Engineering Haul-Truck Components

Replacement parts may be difficult to source when equipment is older, modified or operating with non-standard components.

3D laser scanning can assist with reverse engineering:

Body panels
Floor plates
Sidewall sections
Canopy structures
Access platforms
Guards
Covers
Brackets
Equipment mounts
Ducts
Chutes
Wear liners
Structural attachments

The point cloud can be used as the basis for:

2D profiles
Fabrication drawings
General arrangement drawings
Surface models
Simplified solid models
Clearance envelopes
Interface-control models
Replacement-part geometry

Where high-precision component manufacturing is required, laser scanning may be combined with traditional measurement, portable metrology or other inspection methods.

Supporting Repairs and Engineering Modifications

Mining-equipment modifications often need to be designed within a congested and irregular existing environment.

Scanning can assist with:

Truck-body refurbishment
Structural repair planning
Replacement tray or body integration
Wear-package upgrades
Access improvements
Fire-suppression modifications
Camera and sensor installations
Lighting upgrades
Equipment relocations
Hydraulic-system modifications
Electrical-system installations
Operator-assistance upgrades
Autonomous-system retrofits
Water-cart or service-truck conversions

The scan data gives designers an accurate spatial reference for locating existing structures and checking the available envelope.

This supports design development before fabrication begins.

OEM Drawings Versus Existing-Condition Scanning

OEM drawings, service information and approved repair procedures remain important sources of engineering information.

However, they do not always show:

The present condition of the asset
Site-installed modifications
Previous repairs
Structural distortion
Non-standard attachments
Replacement body arrangements
Wear-liner changes
Locally fabricated components
Actual equipment clearances

Hamilton By Design can use existing OEM information as a reference while capturing the geometry of the physical truck.

This helps establish the difference between:

What was originally designed
What has been modified
What is currently installed
What needs to be repaired or replaced

Any repair or modification affecting structural capacity, braking, steering, suspension, payload, stability or vehicle safety should be assessed and approved by appropriately qualified personnel and completed in accordance with relevant manufacturer requirements, site standards and engineering procedures.

Scan-to-CAD Deliverables

Deliverables can be tailored to suit the project.

They may include:

Registered point cloud
Colourised point cloud
E57 point-cloud files
RCP or RCS files
LAS data
Selected scan views
Orthographic images
Existing-condition drawings
2D sections
Dimensional mark-ups
DWG or DXF files
STEP or SAT geometry
SolidWorks models
Inventor-compatible geometry
Simplified structural models
Surface-deviation comparisons
Before-and-after scan comparisons
Scan-location plans
Inspection notes
Engineering observations

The required modelling detail should be agreed before work begins. A registered point cloud, simplified envelope model and fabrication-ready solid model are different deliverables and require different levels of processing.

Our Haul-Truck Scanning Process

1. Define the Engineering Question

Before scanning, we establish what the project needs to determine.

For example:

Is the truck body deformed?
Will a replacement component fit?
What geometry is required for refurbishment?
Is a previous drawing still accurate?
Can two fleet assets use the same replacement part?
What changed after a structural repair?
Where can new equipment be installed?
Is a repeat-scan monitoring program required?

Defining the engineering question helps determine the scan coverage, resolution and deliverables.

2. Review Available Information

Where available, we review:

OEM drawings
Existing CAD models
Repair drawings
Previous inspection reports
Photographs
Maintenance records
Proposed modifications
Areas of known damage
Required measurement tolerances

3. Prepare the Truck

The best scan results are generally obtained when the equipment is:

Safely isolated
Parked on stable ground
Clean enough to expose the required surfaces
Free from loose material
Accessible around the areas of interest
Positioned to reduce line-of-sight restrictions

Scanning can often be completed in a workshop, maintenance bay, laydown area or suitable mine-site location.

4. Capture the Existing Geometry

Multiple terrestrial laser scans are completed around and, where required, inside the truck body.

The number of scan positions depends on:

Truck size
Required coverage
Surface complexity
Access restrictions
Obstructions
Required point density
Inspection objective
Deliverable requirements

5. Register and Process the Data

The scan positions are aligned into a coordinated point cloud.

The data can then be cleaned, cropped and prepared for engineering use.

6. Develop the Required Outputs

Depending on the scope, the registered point cloud may be used to produce:

Existing-condition drawings
Dimensional checks
Cross-sections
Surface comparisons
CAD models
Repair geometry
Replacement-component models
Engineering-review information

Why Use Hamilton By Design?

Hamilton By Design combines 3D laser scanning with mechanical engineering, drafting and practical manufacturing experience.

Our capability includes:

Engineer-led terrestrial laser scanning
FARO Focus laser-scanning equipment
Existing-condition documentation
Mechanical and structural drafting
Reverse engineering
SolidWorks modelling
Autodesk Inventor and AutoCAD workflows
Scan-to-CAD conversion
Fabrication drawing development
Site measurement and dimensional verification
Engineering support for mining and materials-handling assets

We understand that the value of a scan depends on whether the information can be used by the engineers, maintainers, suppliers and fabricators responsible for the asset.

Our focus is therefore on producing practical data that supports the next stage of the project.

Applications Across a Mining Fleet

The same approach can be extended beyond a single truck.

Potential fleet-wide applications include:

Standardising replacement components
Comparing nominally identical vehicles
Recording body configurations
Developing common liner packages
Confirming component interchangeability
Documenting modifications
Creating digital asset records
Supporting fleet refurbishment programs
Monitoring high-wear zones
Capturing equipment before disposal or rebuild
Developing repeatable repair scopes

Mining companies can also use scanning to develop a more reliable digital record of equipment where drawings, field changes and actual asset condition have become disconnected.

Frequently Asked Questions

Can you scan Caterpillar, Komatsu, Hitachi and Liebherr mining trucks?

Yes. Hamilton By Design provides independent scanning and engineering-data services for mining equipment from different manufacturers.

The scanning method is based on the asset geometry, access conditions and required deliverables rather than a particular truck brand.

Are haul-truck trays also called tubs or bodies?

Yes. Terminology varies between mine sites, manufacturers and suppliers.

Common terms include:

Truck body
Dump body
Haul-truck body
Tray
Tub
Dump tray
Mining body
Off-highway truck body

For SEO and technical clarity, the page should predominantly use “haul-truck body”, while also naturally including tray, tub and dump body throughout the content.

Can scanning measure remaining plate thickness?

Not directly when only one surface of the plate is visible.

Laser scanning records surface geometry. Remaining plate thickness should normally be measured using ultrasonic thickness testing or another appropriate inspection method.

Scan data and thickness measurements can be combined to produce a more complete condition assessment.

Can you compare a worn body with the original design?

Yes, provided a suitable original drawing, CAD model or nominal geometry is available.

Where original digital data is not available, alternative comparisons may be made against a baseline scan, a less-worn area, the opposite side of the body or another similar truck.

The limitations of the selected reference should be clearly documented.

Can you scan a truck before and after refurbishment?

Yes.

Pre-refurbishment and post-refurbishment scans can be used to document changes, check completed work and establish a new baseline for future inspections.

Can scanning help reduce shutdown time?

Scanning can reduce the amount of manual site measurement required and allow design work to progress away from the equipment.

The overall shutdown benefit depends on the project scope, access, required engineering approvals and whether scanning is completed early enough to influence planning and fabrication.

How accurate is the scanning?

Accuracy depends on the scanner, distance, surface condition, scan geometry, registration method and requested output.

Individual scan measurements may achieve millimetre-level precision under suitable conditions. However, the practical accuracy of a complete registered dataset must be assessed against the size of the scanning envelope and project requirements.

Critical dimensions can also be verified with traditional measurement methods where required.

Can the scanning be completed at an operating mine?

Yes, subject to site access, inductions, equipment isolation, work-area controls and an approved scope of work.

Discuss Your Haul-Truck Scanning Requirement

Hamilton By Design provides 3D laser scanning and engineering support for mining haul trucks, truck bodies, trays, tubs, chassis structures and associated components.

We can assist with one-off inspections, refurbishment projects, reverse engineering, fleet standardisation or repeat-scan condition-monitoring programs.

To discuss your project, provide: